Weather shield for underneath a dock leveler

ABSTRACT

A shield system for shielding the area underneath a dock leveler allows a gap to be created either above or below the shield when the deck rises, whereby a shield of a given height dimension can used on dock levelers of various lift heights. In some embodiments, the shield is a pliable curtain that a tensioner holds taut during some operations of the dock leveler, yet the curtain can collapse for below-dock operation. The shield system can be used on horizontally storing dock levelers or vertically storing ones. In some cases, the system includes a pliable web that extends between a front face of the deck and a lip extending from the deck. The web can help seal the area adjacent to a pair of dock bumpers.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.11/268,945, filed Nov. 8, 2005, now U.S. Pat. No. 7,146,673, entitled“Weather Shield for Underneath a Dock Leveler,” and incorporated hereinby reference in its entirety.

FIELD OF DISCLOSURE

The subject disclosure generally pertains to loading docks and morespecifically to a shield system for sheltering an area underneath a dockleveler.

BACKGROUND

A typical loading dock of a building includes an exterior doorway withan elevated platform for loading and unloading vehicles, such as trucksand trailers. To compensate for height differences between the loadingdock platform and an adjacent bed of a truck or trailer, many loadingdocks have a dock leveler. A typical dock leveler includes a deck orramp that is pivotally hinged along its back edge to vary the height ofits front edge. An extension plate or lip extends outward from thedeck's front edge to span the gap between the rear of the truck bed andthe front edge of the deck.

The deck and lip are usually moveable between a stored position and anoperative position. When in the stored position, the deck may be eithervertical or horizontal, depending on the style of dock leveler. U.S.Pat. No. 6,502,268 shows an example of a horizontally storing deck, andU.S. Pat. No. 5,396,676 discloses a dock leveler with a verticallystoring deck. In either case, the lip in the operative position extendsfrom the deck's front edge and rests upon the truck bed to form a bridgebetween the two. This allows personnel and material handling equipmentto readily move on and off the vehicle during loading and unloadingoperations.

To help shield against weather while a vehicle is being serviced at thedock, some type of seal is usually installed around the perimeter of thedoorway. Such seals are typically installed along the upper and sideedges of the doorway to help seal any air gaps that may otherwise existbetween the face of the building and the rear of the vehicle. The dockleveler lip resting upon the rear of the vehicle is often relied upon toseal most of the doorway's lower edge.

The area or pit underneath a dock leveler's deck, however, is usuallyexposed to outside air. This can create problems, particularly whenthere is a significant temperature differential between the indoor andoutdoor air. Warm outside air, for example, may condense underneath arelatively cool deck of a dock leveler used in a cold storage warehouse.The condensation can promote corrosion of various parts of the dockleveler. Conversely, a heated building during the winter may loose asignificant amount of heat by thermal conduction through the deck, ascold outside air cools the ramp from underneath. Thus, regardless ofwhether the outside air is colder or warmer than the inside air, it maybe beneficial to shield the underside of a dock leveler from outsideair, as proposed in U.S. Pat. No. 4,682,382 and the abovementioned '268and '676 patents. These patented shields, however, have theirlimitations.

The '382 patent suggests using a rectangular panel to help shield thearea underneath a dock leveler. A lower edge of the panel is coupled tothe dock, while the panel's upper edge has a resilient sealing strip forsealing against the rear of a vehicle. The effectiveness of that seal,however, may depend on how squarely a vehicle backs into the dock andmay further depend on the shape or contour of the vehicle's rearsurface. Moreover, in the absence of a vehicle, it appears that the dockleveler lip, rather than the rectangular panel, is relied upon to shieldthe underside of the ramp from the outside air. Also, to move the lipfrom a stored, pendant position to an extended, operative position, theramp apparently must lift the lip up and over the upper edge of thepanel before the lip can be set back down atop the truck bed. As the liptravels over the top of the sealing strip, the underside of the ramp maybe momentarily exposed to an inrush of outside air.

The '268 patent discloses a shield that is connected to both theunderside of the deck and the foundation surrounding the pit. Althoughsuch a design works well for new dock leveler installations, such ashield can be difficult to custom fit to an already-existing dockleveler. The shield, for instance, may need to be sized for the deck'sdegree of opening and may need special cutouts to accommodate variouscomponents and operating mechanisms of the dock leveler.

The '676 patent discloses a shield that flexes inward or fartherunderneath the deck as the deck descends. Since dock levelers typicallyhave a lip actuator and/or other operating mechanisms near the frontedge of the deck, a shield flexing inward may interfere with suchmechanisms. Moreover, the '676, '268, and '382 patents fail to disclosean effective way of sealing the area between the underside of anextended lip and adjacent dock bumpers, which are often installed at thedock to establish a predetermined minimum distance between the rear edgeof a truck and the face of the building or front edge of the dockleveler.

Consequently, a need exists for an under leveler seal system thatovercomes the limitations of current systems.

SUMMARY

In some embodiments, a shield system includes a curtain that can bemaintained in vertical tension without the curtain having to span theentire vertical gap between a fully raised deck and the pit.

In some embodiments, the curtain is attached to the deck and can liftaway from the pit.

In some embodiments, the curtain is attached to the pit and the deck canlift away from the curtain.

In some embodiments, the curtain is held in tension by way of atensioner that is attached to the deck.

In some embodiments, the curtain is held in tension by way of atensioner that is coupled to the pit.

In some embodiments, the tensioner includes a spring.

In some embodiments, the tensioner includes a pliable elongate member,such as a cable, strap, cord, chain, or the like.

In some embodiments, the tensioner includes a wheel such as a pulley,sheave or the like.

In some embodiments, a seal system includes a flexible web suspendedfrom a lip of a dock leveler, wherein the web can seal against a frontedge of the deck and/or the side a dock bumper.

In some embodiments, a seal system includes a curtain supported by thetoe guards of a dock leveler.

In some embodiments, the sealing curtain is closer to the upper end ofthe toe guard than the lower end so that curtain can remain generallyplanar.

In some embodiments, the sealing curtain and the toe guard can bothcollapse to facilitate below-dock end loading.

In some embodiments, a collapsible sealing member is supported in agenerally fixed orientation relative to the deck, so that as the deckpivots the seal avoids interfering with operating mechanisms underneaththe deck.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a loading dock with shield system forshielding the area underneath a dock leveler.

FIG. 2 is a side view of the shield system of FIG. 1, wherein the dockleveler is at a stored position.

FIG. 3 is side view similar to FIG. 2 but with the deck raised and thelip partially extended.

FIG. 4 is a side view similar to FIG. 2 but with the lip resting on thetruck bed.

FIG. 5 is a side view similar to FIG. 2 but with the dock leveler in abelow-dock position.

FIG. 6 is similar to FIG. 1 but showing another embodiment of a shield.

FIG. 7 is similar to FIG. 2 but showing the embodiment of FIG. 6.

FIG. 8 is similar to FIG. 3 but showing the embodiment of FIG. 6.

FIG. 9 is similar to FIG. 4 but showing the embodiment of FIG. 6.

FIG. 10 is similar to FIG. 5 but showing the embodiment of FIG. 6.

FIG. 11 is similar to FIG. 2 but showing another embodiment of a shieldsystem.

FIG. 12 is similar to FIG. 3 but showing the embodiment of FIG. 11.

FIG. 13 is similar to FIG. 4 but showing the embodiment of FIG. 11.

FIG. 14 is similar to FIG. 5 but showing the embodiment of FIG. 11.

FIG. 15 is similar to FIG. 2 but showing another embodiment of a shieldsystem.

FIG. 16 is similar to FIG. 3 but showing the embodiment of FIG. 15.

FIG. 17 is similar to FIG. 4 but showing the embodiment of FIG. 15.

FIG. 18 is similar to FIG. 5 but showing the embodiment of FIG. 15.

FIG. 19 is similar to FIG. 2 but showing another embodiment of a shieldsystem.

FIG. 20 is similar to FIG. 3 but showing the embodiment of FIG. 19.

FIG. 21 is similar to FIG. 4 but showing the embodiment of FIG. 19.

FIG. 22 is similar to FIG. 5 but showing the embodiment of FIG. 19.

FIG. 23 is similar to FIG. 2 but showing another embodiment of a shieldsystem.

FIG. 24 is similar to FIG. 3 but showing the embodiment of FIG. 23.

FIG. 25 is similar to FIG. 4 but showing the embodiment of FIG. 23.

FIG. 26 is similar to FIG. 5 but showing the embodiment of FIG. 23.

FIG. 27 is a perspective view similar to FIG. 1 but showing anotherembodiment of a seal system.

FIG. 28 is a partial cutaway perspective view similar to FIG. 1 butshowing another embodiment of a seal system.

DETAILED DESCRIPTION

FIGS. 1-5 show a loading dock 10 with a shield system 12 that includes apliable curtain 14 for shielding a pit area 16 underneath a dock leveler18. By blocking out weather and other elements, curtain 14 helps protectpit area 16. By using a pliable curtain rather than a thicker, morerigid structure, shield system 12, and alternate embodiments thereof,can be readily adapted to fit a wide variety of dock levelers and pits.A curtain, for instance, can be custom cut to size at the installationsite, and various cutouts can be made so that the curtain does not tointerfere with the operation of the dock leveler.

Such trimming is not readily accomplished with thicker foam seals,especially if they are encased within a fabric covering. Moreover, athick foam seal takes up more space underneath a dock leveler than doesa relatively thin curtain.

A pliable curtain, however, is not self-supporting, so shield system 12and various other embodiments herein include some sort of tensioner orsupporting structure that helps support the curtain. Although suchsupporting structure consumes additional space, the supporting structurecan be installed wherever it is most convenient.

With the versatility of curtain 14 and its supporting structure, shieldsystem 12 can be applied to a wide variety of dock levelers, such asthose whose structure and operation are described in U.S. Pat. Nos.6,502,268; 3,137,017; 4,293,969, 5,396,676; 4,776,052; and 6,205,606;all of which are specifically incorporated by reference herein.

For example, dock lever 18 may include a deck 20 that can pivot aboutits rear edge 22 to raise and lower its front edge 24. A lip 26 can bepivotally attached to front edge 24, as explained in the “Background.”The deck of some dock levelers store horizontally, as shown in FIGS. 2,11 and 15 and disclosed in U.S. Pat. Nos. 6,502,268; 3,137,017; and4,293,969. Other decks store vertically, as shown in FIGS. 19 and 23 anddisclosed in U.S. Pat. Nos. 5,396,676; 4,776,052; and 6,205,606. Themechanisms for pivoting deck 20 and lip 26 have not been shown so as tonot interfere with the illustration of other features of the dockleveler 18. However, such mechanisms are well known in the industry.

The operating sequence of dock leveler 18 and shield system 12 may beginwith deck 20 in its stored, cross-traffic position, as shown in FIG. 2.In this position, lip 26 may be supported by a set of lip keepers 28 sothat lip 26 and keepers 28 can help hold deck 20 in its generallyhorizontal position. With dock leveler 18 in its stored position, avehicle 30, such as a truck, trailer, or the like, can back into dock 10until the rear end of vehicle 30 engages or is adjacent to a set ofbumpers 32.

To help shield pit area 16, curtain 14 has a lower edge 34 attached tothe loading dock's front face 36, just below pit 16. A tensioner 38attached to an upper edge 40 of curtain 14 applies vertical tension tocurtain 14. The tension helps keep curtain 14 generally upright in frontof pit area 16, i.e., between an upper surface 42 of pit 16 and a lowersurface 44 of deck 20. Curtain 14 can be made of any pliable orsemi-flexible material including, but not limited to, nylon, canvas,HYPALON (Dupont trademark), canvas duck, rubber impregnated fabric,foam, etc. Curtain 14 may include various notches 46 or cutouts 48 toaccommodate lip keepers 28, vehicle restraints, or other components.

Tensioner 38 represents any structure that can create vertical tensionin curtain 14. In one example, tensioner 38 comprises one or morepliable elongate members 50 (e.g., cable, strap, chain, cord, etc.)extending between the curtain's upper edge 40 and an anchor point 52 ondeck 20. In some embodiments, a spring 54 (e.g., helical spring, elasticcord, gas spring, etc.) coupled to member 38 can be used to maintaintension in member 38 as deck 20 pivots up and down, and a wheel 56(e.g., pulley, sheave, etc.) allows the tension to be applied to curtain14 in a generally vertical direction. In other embodiments, a deadweightor counterbalance can be used for creating the vertical tension incurtain 14.

After vehicle 30 engages or is sufficiently close to bumpers 32, avehicle restraint 58 may raise its barrier 60 to engage the vehicle'sICC bar 62, thereby helping hold vehicle 30 in position. The use of avehicle restraint to engage a vehicle's ICC bar is well known in theindustry and is disclosed in U.S. Pat. Nos. 4,560,315; 5,702,223; and6,106,212; all of which are specifically incorporated by referenceherein.

Once vehicle 30 is in the position shown in FIG. 3, deck 20 rises sothat lip 26 can be extended and subsequently lowered back down to restupon the vehicle's truck bed, as shown in FIG. 4. When deck 20 israised, as shown in FIGS. 1 and 3, upper edge 40 of curtain 14 and lowersurface 44 of deck 20 define a gap 64 therebetween. Gap 64 has a height66 that varies with the pivotal movement of deck 20. Being able tocreate gap 64 while still maintaining tension in curtain 14 allows acurtain of a given height to fit various dock levelers even though theirdecks may rise to different levels. Moreover, being able to create gap64 means that curtain 14 does not have to extend fully up to the maximumlift height of deck 20, thus curtain 14 can be shorter than if upperedge 40 were directly attached to deck 20.

In comparing FIGS. 2 and 3, it should be noted that as deck 20 rises,spring 54 stretches to accommodate the increased distance between wheel56 and the curtain's upper edge 40.

With dock leveler 18 in the position of FIG. 4, vehicle 30 can be loadedand unloaded of its cargo while curtain 14 provides an effective barrierthat helps keep pit area 16 clean and dry, as the height of gap 64 isnow minimal or nonexistent.

For end-loading or other below-dock operations, dock leveler 18 can bepositioned as shown in FIG. 5. In this position, deck 20 lowers lip 26below its lip keepers 28. Even though the vertical distance between thedeck's lower surface 44 and the upper surface 42 of pit 16 is less thanthe full height of curtain 14, below-dock operation is still possibledue to the flexibility of curtain 14, which allows curtain 14 tocollapse under pressure from deck 20.

FIGS. 6-10 illustrate an alternate shield system 140 where pliablecurtain 14 is supported by a collapsible supporting structure 142. Withthis design, curtain 14 can be trimmed at the installation site to fitany pit, dock leveler and associated hardware. Once cut to size, anynumber of supporting structures 142 can be mounted to the pit floor orother anchor point and attached to curtain 14 at any suitable locationthat does not interfere with the operation of dock leveler 18.Structures 142 can be fastened to curtain 14 by any suitable meansincluding, but not limited to, threaded fasteners, VELCRO, adhesive,straps, rope, and clamps. Structure 142 is schematically illustrated torepresent any body that can be collapsed under pressure and laterresiliently recover its original shape. Examples of structure 142include, but are not limited to, a foam block or column, a helical orleaf spring, a telescoping member (e.g., piston/cylinder, air spring,shock absorber, etc.), rubber or other polymeric rod, and variouscombinations thereof. In some cases, structure 142 may be encased withina protective fabric jacket.

The operation of shield system 140 is comparable to that of system 12with FIGS. 6, 7, 8, 9 and 10 corresponding to FIGS. 1, 2, 3, 4 and 5respectively. When deck 20 is in a cross-traffic position, as shown inFIG. 7, the upper edge of curtain 14 and supporting structure 142 isadjacent to the lower surface of deck 20. Supporting structure 142 holdscurtain 14 relatively taut in front of pit 16 so that system 140 caneffectively shelter the area under deck 20. Since deck 20 is notattached to system 140, deck 20 is free to pivot to a raised position,as shown in FIG. 8. The collapsibility of curtain 14 and structure 142allows deck 20 to descend to a below-dock position, as shown in FIG. 10.

FIGS. 11-14 illustrate an alternate shield system 68 that includescurtain 14. Shield system 68 is similar to system 12 with FIGS. 11, 12,13 and 14 corresponding to FIGS. 2, 3, 4 and 5 respectively. Shieldsystem 68 has a curtain tensioner 70 comprising a spring 72, an elongatemember 74, and a wheel 76 that are similar to corresponding items oftensioner 12. However, wheel 76 and an anchor point 78 can be attachedto any convenient point of the loading dock rather than having to beattached to deck 20. Wheel 76, for instance, could be attached to asidewall of pit 16, and anchor point 78 could be attached to the floorof the pit. By allowing the separation of tensioner 70 and deck 20,tensioner 70 can be shorter because the tensioner 70 does not have tospan the maximum lift distance of the deck 20. The flexibility ofcurtain 14 still allows below-dock operation as shown in FIG. 14.Although curtain tensioner 70 comprises spring 72, elongate member 74and wheel 76 to apply vertical tension in curtain 14, a wide variety ofother spring loaded mechanisms mounted within pit 16 and separated fromdeck 20 could be used for holding curtain 14 taut.

In another embodiment, shown in FIGS. 15-18, a shield system 80 includesa flexible curtain 82 suspended from deck 20. Curtain 82 is heldvertically taut by way of a tensioner 84 that includes two spring-loadedarms 86, an upper arm 86 a and a lower arm 86 b. Each arm 86 a and 86 bhas a distal end attached to curtain 82, and the two arms are joined ata central pivot point 88. A torsion spring can be used to urge thedistal ends of arms 86 a and 86 b apart so that they impart verticaltension in curtain 82. FIGS. 15, 16, 17 and 18 correspond to FIGS. 2, 3,4 and 5 respectively. The flexibility of curtain 82 and arms 86 beingable to pivot about point 88 under the urging of the torsion springallow below-dock operation as shown in FIG. 18.

In another embodiment, shown in FIGS. 19-22, a shield system 90 includesa flexible curtain 92 suspended from a vertically storing pivotal deck94 and supported by one or more foam blocks 96. FIGS. 19, 20, 21 and 22correspond to FIGS. 2, 3, 4 and 5 respectively. Although shield system90 is shown mounted to a vertically storing dock leveler 98, system 90could also be installed on horizontally storing dock levelers, such asdock leveler 18. In FIGS. 19-21, foam block 96 helps keep curtain 92 ina generally fixed orientation relative to deck 94. In FIG. 22, however,the flexibility of curtain 92 and foam block 96 allow below-dockoperation.

Shield system 90 also includes flexible webs 100 that help seal the gapthat may otherwise exist between lip 26 and bumper 32. In someinstallations, web 100 has one edge 102 (FIG. 21) attached to theunderside of lip 26 and another edge 104 attached to curtain 92 and/ordeck 94. Web 100 is sufficiently flexible to collapse as lip 26 pivotstoward deck 94, as shown in FIGS. 19, 20 and 22. FIG. 21 shows how web100 can deform in reaction to vehicle 30 backing into the dock. Althoughweb 100 is shown installed to dock leveler 98, web 100 could beinstalled on a wide variety of dock levelers including, but not limitedto, all of the dock levelers disclosed in FIGS. 1-28. Moreover, web 100could be installed on dock levelers that have additional seals otherthan those disclosed herein or installed on dock levelers that have noadditional seals whatsoever. FIG. 27 shows a perspective view of twowebs 100 installed on a dock leveler 106.

FIGS. 23-26 show a shield system 108 similar to shield system 90 withFIGS. 23, 24, 25 and 26 corresponding to FIGS. 19, 20, 21 and 22respectively. With shield system 108, curtain 92 is held taut by one ormore leaf springs 110 (e.g., bands of spring steel) instead of beingsupported by foam blocks 96. Otherwise, shield systems 108 and 90operate in a similar manner.

FIG. 27 shows a shield system 118 that includes a curtain 120 orflexible shield attached to a right toe guard 122 and a left toe guard124 of dock leveler 106. Curtain 120 has an upper edge 126 attached todeck 20. A lower edge 128 can be directly attached to toe guards 122 and124, as shown in FIG. 27, or an extension bracket 130 can couple loweredge 128 of curtain 120 to a lower segment of the toe guards, as shownin FIG. 28. The toe guards help prevent someone from accidentallygetting their foot pinched between the deck and the dock as the deckmoves down to a cross-traffic position. As the deck descends, the toeguards can collapse, for each toe guard 122 and 124 comprises aplurality of segments 132 and 134 that can move relative to each other.Although their actual structure may vary, some examples of toe guardsand how they function are disclosed in U.S. Pat. Nos. 3,456,274;4,928,340; 4,557,008; and 4,110,860; all of which are specificallyincorporated by reference herein.

Referring to FIG. 28, flexible fingers or tabs 136 can be attached toweb 100 to improve the sealing between web 100 and bumper 32.

Although the invention is described with respect to various embodiments,modifications thereto will be apparent to those of ordinary skill in theart. The various curtains, for example, are shown as being attached tothe pit and separated from the deck or vice versa; however, it isconceivable and well within the scope of the invention to have a splitcurtain comprising two curtain sections with one section attached to thedeck and the other section attached to the pit. With a split curtaindesign, the two sections would separate as the deck rises and wouldoverlap or come together when the deck returns to its lowered position.Therefore, the scope of the invention is to be determined by referenceto the following claims.

1. A dock leveler shield system useable at a loading dock, comprising: apivotal deck; a lip pivotally coupled to the pivotal deck, wherein thelip has an upper traffic-bearing surface, a rear surface substantiallyperpendicular to the upper traffic-bearing surface, and a lateralsurface that is substantially perpendicular to both the uppertraffic-bearing surface and the rear surface; and a flexible webattached to the lip and extending below the lip in a substantiallyparallel relationship with the lateral surface such that the flexibleweb spans a gap between the pivotal deck and a vehicle parked in thevicinity of the loading dock when the pivotal deck and the lip are in anoperational position.
 2. The dock leveler shield system of claim 1,wherein the flexible web collapses in response to the lip pivotingtoward the pivotal deck.
 3. The dock leveler shield system of claim 1,further comprising a pair of bumper structures between which the lip canpivot, wherein the web sealingly engages the pair of bumper structureswhen the web is positioned therebetween.
 4. The dock leveler shieldsystem of claim 1, further comprising a flexible shield attached to thepivotal deck, wherein the flexible web includes one edge attached to thelip and another edge attached to the flexible shield.
 5. The dockleveler shield system of claim 1, further comprising a toe guard coupledto the pivotal deck such that the toe guard is substantiallyperpendicular to the pivotal deck.